Proceedings of 4th RIT Post Graduates Conference (RIT PG Con-18) NOVATEUR PUBLICATIONS JournalNX- A Multidisciplinary Peer Reviewed Journal (ISSN No:2581-4230) April, 13th, 2018
COMPARISON OF WEIGHTS OF STEEL AND COMPOSITE COIL SPRING FOR TWO WHEELER SUSPENSION SYSTEMS Rajaram M. Shinde 1
Soham P. Godase 2
Automobile Engg. Dept. Rajarambapu Institute of Technology Islampur, Sangli, India. rajaram.shinde@ritindia.edu
Automobile Engg. Dept. Rajarambapu Institute of Technology Islampur, Sangli, India. godasesoham@gmail.com
Suresh M. Sawant 3
Professor, Mechanical Engg. Dept. Rajarambapu Institute of Technology Islampur, Sangli, India. suresh.sawant@ritindia.edu Abstract—Thepresent article givesinformation on design of steel and composite coil spring for twowheelerapplication. The reason to develop the composite coil spring is to minimize the weight of coil spring. In this article, study has been done on a two-wheeler vehicle. Dimensions of the exiting steel coil spring are measured. The load on the spring has been calculated mathematically. Deflection, shear stress, weight and stiffness are calculated using dimensions of existing steel coil spring.The design of composite coil spring has been done as same stiffness as that of steel spring byusingtrial and error method. The metal coil spring weight was 0.782 kg and the newly developed composite coil spring has 0.244 kg. So, weight of the existing coil spring has been reduced by 70% using composite coil spring. Keywords—composite material, carbon fiber, steel coil spring, epoxy, composite coil spring.
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I. INTRODUCTION Spring is an elastic machine element. When the load is applied, the spring getsdeflects and when the load is removed then spring returns to its original shape. Spring is used in vehicle to absorb shock and vibrations. Also, it is used to store the energy. The composite materials have low weight as compared to metallic material. So, we can replace metal coil spring by composite coil spring. It has high strain energy, less weight and high corrosion resistance. The composite coil spring is the combination of two or more materials. The material used for the composite coil has fibers and matrix, the combination of both makes it a strong material. Research has been carried out related to composite material coil spring of which some they are discussed. Max A. Sardou et al. [1] have present information on the practical reality of composite coil spring. They give information about how to manufacture the composite coil spring also gives the information about the physical properties of various composite materials which is used for manufacturing the coil springs, different test for manufactured composite coil springs. Daewon Jang and Sungbae Jang [2] have developed a light-weight carbon fiber reinforced plastic coil spring. The composite material properties of CFRP were predicted through analysis.
Mean coil diameter Wire diameter Active number of turns Spring index Density Stiffness Weight of spring Shear stress Wahl’s factor Deflection Shear modulus of matrix Shear modulus of fiber in longitudinal and transverse direction Fiber volume fraction Elastic modulus of matrix Elastic modulus of fiber.
A spring rate of spring is accorded with design goal and various tests to verify the performance of the spring was performed. The developed suspension spring is lighter than half weight compared to conventional spring.Bok-Lok Choi and Byoung-Ho Choi [3] designed a carbon fiber reinforced epoxy composite coil spring by using numerical methods.CFRP coil spring manufactured using the resin transfer molding (RTM) process. Ply angle in composite beam is used to determine the optimum wire diameter of the coil spring.The static spring rate of CFRP coil spring is calculated in Finite element analysis. The analytical test was taken to verify the result of FEA. Ekanthappa J. et. al. [4] has carried out research on the fabrication and experimentation of the glass epoxy helical spring reinforced with graphite powder. Modified filament winding technique is used for fabrication of spring. Two types of composite coil spring are developed; first is glass/epoxy and the second is glass/ epoxy+ graphite power. The mass of composite coil spring is 40% less than metal coilspring.Chang-Hsuan Chiu et. al. [5] has done an experimental investigation into the mechanical behaviors of helical composite springs. Four different types of helical composite spring’s structure were made. The experimental test is carried out to investigate the effects of rubber core
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